US20250276225A1

US20250276225A1 - Sports paddle

Info

Publication number: US20250276225A1
Application number: US19/209,630
Authority: US
Inventors: Mitch Junkins
Original assignee: Individual
Current assignee: Individual
Priority date: 2022-05-09
Filing date: 2025-05-15
Publication date: 2025-09-04

Abstract

An apparatus and methods are provided for a sports paddle for pickleball, tennis, smashball, ping pong, or racquetball. The sports paddle comprises a planar portion for striking a ball and a handle portion for grasping in a hand. A skin layer encloses the planar portion and the handle portion. Rounded edges are disposed around the planar portion and the handle portion. The planar portion may comprise an internal string core coupled with structured foam layers and surrounded by carbon fiber layers. The planar portion may comprise a core material surrounded by a rigid portion. The rigid portion may comprise 20-24 lb. foam while the core material is a honeycomb structured material. A synthetic or polymeric grip is wrapped around the handle portion to provide stability and firmness for a player. A binding secures the grip to a neck of the planar portion.

Description

PRIORITY

This application is a continuation-in-part of, and claims the benefit of, U.S. patent application, entitled “Sports Paddle,” filed on May 8, 2024, and having application Ser. No. 18/658,701, which claims the benefit of, and priority to, U.S. patent application, entitled “Sports Paddle,” filed on May 8, 2023, and having application Ser. No. 18/144,770, which claims the benefit of, and priority to, U.S. Provisional application, entitled “Sports Paddle,” filed on May 9, 2022, and having application Ser. No. 63/339,855, and to U.S. Provisional application, entitled “Sports Paddle,” filed on Oct. 15, 2022, having application Ser. No. 63/419,154, and to U.S. Provisional application, entitled “Core Strung Sports Paddle,” filed on Feb. 5, 2025, having application Ser. No. 63/754,416, the entirety of each of said applications being incorporated herein by reference.

FIELD

Embodiments of the present disclosure generally relate to paddles for sports. More specifically, embodiments of the disclosure relate to an apparatus and methods for a sports paddle for pickleball, tennis, smashball, paddle tennis, ping pong, or racquetball.

BACKGROUND

Pickleball typically is played on a badminton-sized court with a tennis-like net, using a perforated plastic hollow ball. The ball is struck by players using pickleball paddles that resemble large table tennis paddles. Pickleball paddles generally are be made from wood, graphite, aluminum, carbon fiber, fiberglass, composite materials, and other suitable materials. They often have a polypropylene or foam core.
Pickleball paddles may be constructed by cutting or machining a large sheet of material into the shape of a paddle or by surrounding the core in a composite material and allowing it to cure in a fixed tool. As shown in FIG. 1 , a conventional paddle 100 generally includes a ball striking, planar portion 104 and a handle portion 108. The planar portion 104 defines opposing flat surfaces. An outer edge guard 112 generally is provided around the planar portion 104 to protect core material comprising the planar portion 104. The planar portion 104 extends downward into the handle portion 108. A synthetic or polymeric grip 116 is wrapped around the handle portion 108 to provide stability and firmness for the player. A binding 120 secures the grip 116 to a neck 124 of the paddle 100. An end cap 128 placed at an end of the handle 108 provides support and protection of the paddle 100.
The opposing flat surfaces of the paddle 100 may be covered by a skin or protective layers. The skin is sometimes called a “laminate” or “face sheet.” In embodiments where a core material is bonded to a skin material, the paddle 100 is referred to as a “composite panel” or “sandwich panel.” The skin material may comprise thin, but stiff, skins while the core material may comprise a lightweight, but thick, core. The core material generally is low strength material, but its greater thickness provides the sandwich panel with high bending stiffness and low overall density.
The core material may comprise open-cell-structures and closed-cell-structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like. Open-cell and closed-cell metal foam can also be used as core materials.
Laminates comprising glass or carbon fiber-reinforced thermoplastics or thermoset polymers, such as unsaturated polyesters, epoxies, and the like, may be used as skin materials. Sheet metal may also be used as skin material.
A drawback to conventional paddles is that they tend to develop weak spots or soft spots, known as “dead spots.” Dead spots typically form at locations where wear damage occurs, or where the adhesive fails, resulting in delamination of the skin material from the core material. Dead spots can also occur because edges of conventional paddles are held together only by a flexible rail guard that allows the paddle edges to flex during ball impacts.
Another drawback to conventional paddles comprising sandwich panels, such as the paddle 100, arises due to edge treatments. Some manufacturers apply a U-channel or other type of molding, such as the edge guard 112, to protect the edge of the planar portion 104 and enclose the periphery of the core material disposed between the skin materials. The edge guard 112 forms a lip 132 around the planar portion 104 that creates interference when striking the ball in this area of the paddle 100. Further, some manufacturers finish the edge with a composite material. Unfortunately, the composite material renders the edge of the paddle 100 overly fragile, resulting in damage if the ground or a hard object is struck during play. Moreover, many methods of finishing the edge of the paddle 100 cause reliability issues, such as the edge treatment tending loosen and separate or fall off with age or stress. Additionally, in some instances a flexible rail guard may be used, but such rail guards often cause undesirable ball trajectories when struck by the ball during play.
There is a need, therefore, for a paddle that does not require an edge treatment, such as the edge guard 112 shown in FIG. 1 .

SUMMARY

An apparatus and a method are provided for a sports paddle for pickleball, tennis, smashball, ping pong, or racquetball. The sports paddle comprises a planar portion defining opposing flat surfaces for striking a ball and a handle portion for grasping in a hand. A skin layer encloses the planar portion and the handle portion. Rounded edges are disposed around the planar portion and the handle portion. The planar portion may comprise an internal string core coupled with structured foam layers and surrounded by carbon fiber layers. The planar portion may comprise a core material surrounded by a rigid portion. The rigid portion may comprise 20-24 lb. foam while the core material is a honeycomb structured material. A synthetic or polymeric grip is wrapped around the handle portion to provide stability and firmness for a player. A binding secures the grip to a neck of the planar portion. An end cap placed at an end of the handle provides support and protection of the paddle.
In an exemplary embodiment, a sports paddle comprises: a planar portion having opposing flat surfaces for striking a ball; a core material having rounded edges; a handle portion for grasping in a hand; and a skin layer surrounding at least a majority of the planar portion.
In another exemplary embodiment, the planar portion includes a shaped core material and a rigid portion. In another exemplary embodiment, the shaped core material comprises a window-like structure that provides a planar portion that exhibits a relatively greater degree of rigidity.
In another exemplary embodiment, one or more weights are incorporated into the planar portion to increase the weight of the paddle. In another exemplary embodiment, any one or more of the one or more weights comprises a stabilizer that provides desired performance results. In another exemplary embodiment, any one or more of the multiple weights and the stabilizers comprise slugs of gel rubber for weighing the paddle and/or creating a dampening of vibration. In another exemplary embodiment, any one or more of the multiple weights and the stabilizers comprises a first weight and a second weight that are embedded on opposite sides of the core.
In another exemplary embodiment, the planar portion comprises multiple stringers that are embedded in the core material. In another exemplary embodiment, the multiple stringers comprise strips of wood or plastic that are glued into the core material. In another exemplary embodiment, the multiple stringers comprise rubber, a foam, or another suitable material that provides a flexible planar portion. In another exemplary embodiment, one or more of the multiple stringers comprises a curved stringer that is embedded into the planar portion.
In another exemplary embodiment, the planar portion comprises a rigid portion that includes a core material having one or more channels that are arranged in a pattern that desirably enhances the performance of the paddle. In another exemplary embodiment, any one or more of the one or more channels extends all the way through the core material. In another exemplary embodiment, any one or more of the one or more channels comprises a first channel and a second channel that are disposed on opposite sides of the planar portion, leaving a relatively thin portion of the core material disposed between the first channel and the second channel.
In another exemplary embodiment, the planar portion includes an internal string core surrounded by structured foam layers. In another exemplary embodiment, the string core is strung on a rigid portion comprising carbon fiber, aluminum, or another similar material capable of supporting the string core. In another exemplary embodiment, a rigid layer is disposed outside each structured foam layer.
In another exemplary embodiment, the planar portion includes a core material surrounded by an external string core that is strung around the exterior of a rigid portion. In another exemplary embodiment, the rigid portion comprises carbon fiber, aluminum, or another similar material. In another exemplary embodiment, the external string core and the rigid portion surround an interior volume that houses the core material.
These and other features of the concepts provided herein may be better understood with reference to the drawings, description, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates a perspective view of an exemplary embodiment of a conventional paddle that includes an edge guard;

FIG. 2 illustrates a side view of an exemplary embodiment of a sports paddle, in accordance with the present disclosure;

FIG. 3 illustrates an edge view of an exemplary embodiment of a sports paddle that includes rounded edges, according to the present disclosure;

FIG. 4 illustrates a side view of an exemplary embodiment of a sports paddle that includes a core material in accordance with the present disclosure;

FIG. 5 illustrates an exploded side view of an exemplary embodiment of a sports paddle that includes an internal string core surrounded by structured foam layers in accordance with the present disclosure;

FIG. 6 illustrates a close-up view of an exemplary embodiment of a sports paddle that includes a core material surrounded by an external string core in accordance with the present disclosure;

FIG. 7 illustrates an exploded side view of an exemplary embodiment of a sports paddle that includes a core material surrounded by an external string core according to the present disclosure;

FIG. 8 illustrates a side view of an exemplary embodiment of a sports paddle that includes a core material in accordance with the present disclosure;

FIG. 8A illustrates a side view of an exemplary embodiment of a sports paddle that includes a shaped core material and a rigid portion in accordance with the present disclosure;

FIG. 8B illustrates a side view of an exemplary embodiment of a sports paddle that includes a shaped core material and a rigid portion according to the present disclosure;

FIG. 9 illustrates a side view of an exemplary embodiment of a sports paddle that includes a core material and a padded edge guard in accordance with the present disclosure;

FIG. 10 illustrates a side view of an exemplary embodiment of a sports paddle that includes multiple weights according to the present disclosure;

FIG. 11A illustrates a cross-sectional view of an exemplary embodiment of an edge guard that may be coupled with an exterior of a periphery of the sports paddle;

FIG. 11B illustrates a cross-sectional view of an exemplary embodiment of an edge guard that may be coupled with an exterior of a periphery of the sports paddle;

FIG. 12 illustrates a side view of an exemplary embodiment of a sports paddle that includes stringers of a rigid material according to the present disclosure;

FIG. 12A illustrates a cross-sectional view of the sport paddle of FIG. 12 , taken along line 12A-12A, in accordance with the present disclosure;

FIG. 13 illustrates a side view of an exemplary embodiment of a sports paddle that includes curved stringers of a rigid material according to the present disclosure;

FIG. 14 illustrates a side view of an exemplary embodiment of a sports paddle that includes curved stringers of a rigid material in accordance with the present disclosure;

FIG. 14A illustrates a side view of an exemplary embodiment of a sports paddle that includes a combination of curved stringers and linear stringers of a rigid material according to the present disclosure;

FIG. 14B illustrates a side view of an exemplary embodiment of a sports paddle that includes a combination of circular stringers and elliptical stringers of a rigid material accordance with the present disclosure;

FIG. 15 illustrates a side view of an exemplary embodiment of a sports paddle that includes multiple stabilizer slugs or balance slugs according to the present disclosure;

FIG. 15A illustrates a cross-sectional view of the sport paddle of FIG. 15 , taken along line 15A-15A, in accordance with the present disclosure;

FIG. 15B illustrates a cross-sectional view of an alternative embodiment of the sport paddle of FIG. 15 , taken along line 15A-15A, according to the present disclosure;

FIG. 16 illustrates a side view of an exemplary embodiment of a sports paddle that includes channels or holes according to the present disclosure;

FIG. 16A illustrates a cross-sectional view of the sport paddle of FIG. 16 , taken along line 16A-16A, in accordance with the present disclosure; and

FIG. 16B illustrates a cross-sectional view of an alternative embodiment of the sport paddle of FIG. 16 , taken along line 16A-16A, according to the present disclosure.

While the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. The present disclosure should be understood to not be limited to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure. It will be apparent, however, to one of ordinary skill in the art that the paddle and methods disclosed herein may be practiced without these specific details. In other instances, specific numeric references such as “first core material,” may be made. However, the specific numeric reference should not be interpreted as a literal sequential order but rather interpreted that the “first core material” is different than a “second core material.” Thus, the specific details set forth are merely exemplary. The specific details may be varied from and still be contemplated to be within the spirit and scope of the present disclosure. The term “coupled” is defined as meaning connected either directly to the component or indirectly to the component through another component. Further, as used herein, the terms “about,” “approximately,” or “substantially” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of components to function for its intended purpose as described herein.
Pickleball paddles generally are be made from wood, graphite, aluminum, fiberglass, carbon fiber, composite materials, and other suitable materials. In many embodiments, a core material is bonded between sheets of a skin material. A drawback to conventional paddles is that they tend to develop dead spots at locations where wear damage occurs, or where the adhesive fails, resulting in delamination of the skin material from the core material. Another drawback arises due to edge treatments, such as an edge guard used to protect the edge of the planar portion and enclose the periphery of the core material disposed between the skin materials. The edge guard forms a lip around the planar portion that creates interference when striking the ball in this area of the paddle. Embodiments presented herein provide a paddle that does not require an edge guard, allowing the paddle to be made out of a continuous material that encloses the core material as well as any structures incorporated into the core.
FIG. 2 illustrates an exemplary embodiment of a paddle 140 that obviates any need for an edge treatment, such as the edge guard 112, in accordance with the present disclosure. The paddle 140 includes a planar portion 144 and a handle portion 148. The planar portion 144 defines opposing flat surfaces for striking a pickleball. The planar portion 144 comprises a core material, as described herein. The planar portion 144 extends into the handle portion 148. A synthetic or polymeric grip 152 is wrapped around the handle portion 148 to provide stability and firmness for the player. In some embodiments, the grip 152 may be wrapped around hardwood portions (not shown) that may be coupled with the handle portion 148. In some embodiments, the grip 152 may be wrapped around portions comprising EVA foam (not shown), or another suitable material, that may be coupled with the handle portion 148. It is contemplated that a wide variety of materials may comprise the portions coupled with the handle portion 148, without limitation. A binding 156 secures the grip 152 to a neck 160 of the paddle 140. An end cap 164 placed at an end of the handle 148 provides support and protection of the paddle 140.
As shown in FIG. 2 , the core material comprising paddle 140 is wrapped within a skin layer 168. Unlike conventional paddles that comprise a sandwich panel structure, the skin layer 168 may surround an entirety of the core material. As shown in FIG. 3 , enclosing the core material within the skin layer 168 enables incorporating rounded edges 172 into the planar portion 144 and the handle portion 148 without requiring an edge treatment, such as the edge guard 112 shown in FIG. 1 . Once the skin layer 168 is applied to the planar portion 144 and the handle portion 148, the grip 152, the binding 156, and the end cap 164 may be installed onto the paddle 140 as shown in FIG. 2 .
The skin layer 168 may comprise fiberglass, graphite, carbon fiber, or other suitable material that offers a practitioner a sense of control, feel, or power during play. In some embodiments, the opposing sides of the planar portion 144 may be covered by skin layers 168 comprising different materials, thereby forming a “hybrid” paddle that offers differing performance on the opposing sides. For example, one side may offer greater power while the other side offers greater precision. Further, in some embodiments, the skin layers 168 may be laminates comprising glass or carbon fiber-reinforced thermoplastics or thermoset polymers, such as unsaturated polyesters, epoxies, and the like, as well as sheet metal, without limitation. Further, in some embodiments, the skin layers 168 may be configured to provide specific performance properties, such as, for example, a consistent traction. In some embodiments, the skin layers 168 may include permanent or removeable film portions that are configured to provide desired performance properties, such as a consistent traction, without limitation. In some embodiments, adhesive stickers comprising carbon fiber sheets may be configured to provide consistent or enhanced traction. It is contemplated that such adhesive stickers may be applied to and removed from the planar portion 144 of the paddle 140 as desired.
In some embodiments, the skin layer 168 may be configured to provide noise suppression properties. As such, in some embodiments, the skin layer 168 may include adhesive stickers comprising a synthetic rubber compound, such as by way of non-limiting example, neoprene or ethylene propylene diene monomer (EPDM), and the like. It is contemplated that, in some embodiments, the noise suppressing stickers can be applied to and removed from the planar portion 144 of the paddle 140, as desired. In some embodiments, the skin layer 168 may comprise fixed foam surfaces that cover the planar portion 144 of the paddle 140. Further, in some embodiments, the skin layer 168 may comprise a removeable skin that is configured to be pulled onto the planar portion 144 and then closed onto the paddle 140. It is contemplated that the removeable skin includes a zipper or similar device for enclosing the planar portion 144. In some embodiments, the removeable skin may include foam portions configured to dampen the sound of striking a ball with the paddle 140. As will be appreciated, applying noise damping properties to the paddle 140 is particularly useful for playing pickleball or other similar games near residences.
The core material may comprise open-cell-structures and closed-cell-structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like. Open-cell and closed-cell metal foam can also be used as core materials. In one embodiment, the core material comprises a complete polypropylene honeycomb core that is wrapped in 4 layers of pre-preg carbon fiber. The carbon fiber is adhered to the honeycomb and baked under compression to form a “boned surface.” In one embodiment, the core material comprises between 20-lb. and 24-lb. foam. Other suitable materials will be apparent to those skilled in the art.
Moreover, in some embodiments, the polypropylene honeycomb is dipped into a bath of a liquid material that remains flexible in a dried state. The liquid material may comprise any one or more of rubber, Urethanes, as well as exotic materials such as liquid diamond dust, liquid carbon fiber, liquid Kevlar, liquid gold dust, liquid ruby dust, and the like. Once the liquid material is dried onto the honeycomb core, the core is wrapped in 4 layers of pre-preg carbon fiber. The carbon fiber is adhered to the honeycomb and baked under compression to form a boned surface, as mentioned above. It is contemplated that the dried liquid material can be used to change the properties of the paddle 140, such as change weight, construction strength, bounce, and the like. Further, it is contemplated that dipping the honeycomb core seals off the honeycomb chamber walls, preventing small pieces from coming off causing rattles.
It is contemplated that any of various structures may be incorporated into the planar portion before being wrapped in the skin layers 168, as described herein. For example, FIG. 4 illustrates an exemplary embodiment of a paddle 180 that includes a structured planar portion 184 and a handle portion 188 in accordance with the present disclosure. The planar portion 184 and the handle portion 188 have rounded edges 192, as described herein. The planar portion 184 comprises a core 196 surrounded by a rigid portion 200. The core 196 and the rigid portion 200 may comprise any of various materials that are found to provide a product that can be more efficiently produced, that is more aesthetically pleasing, that provides greater consistency of function, and is more reliable than products produced using other technologies. In some embodiments, the rigid portion 200 comprises a carbon fiber or aluminum frame while the core 196 comprises an internal string core that is sandwiched between polypropylene or foam layers.
FIG. 5 illustrates an exploded side view of an exemplary embodiment of a sports paddle 204 that includes an internal string core 208 surrounded by structured foam layers 212 in accordance with the present disclosure. The string core 208 is strung, and dynamically tensioned, on a rigid portion 216. Like the rigid portion 200 mentioned above, the rigid portion 216 comprises carbon fiber, aluminum, or another similar material capable of supporting the string core 208. A structured foam layer 212 is positioned above and below the string core 208. The structured foam layers 212 can comprise any of polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like, without limitation. As shown in FIG. 5 , a rigid layer 220 is disposed outside each structured foam layer 212. The rigid layers 220 can comprise multilayer carbon fiber, fiberglass, or another similar material, without limitation. It is contemplated that, in some embodiments, the paddle 204 can be wrapped within a skin layer 168, as described herein.
FIG. 6 illustrates a close-up view of an exemplary embodiment of a sports paddle 224 that includes a core material 228 surrounded by an external string core 232 in accordance with the present disclosure. As shown in FIG. 6 , the string core 232 is strung around the exterior of a rigid portion 236. The rigid portion 236 can comprise carbon fiber or another similar material. In some embodiments, the rigid portion 236 comprises aluminum or a suitable composite material. It is contemplated that the string core 232 can be strung on either one or both sides of the rigid portion 236. In embodiments wherein the string core 232 is strung on both sides of the rigid portion 236, the string core 232 and the rigid portion 236 surround an interior volume that can house the core material 228.
FIG. 7 illustrates an exploded side view of an exemplary embodiment of a sports paddle 224 that includes a core material 228 surrounded by an external string core 232 that is strung on a rigid portion 236 according to the present disclosure. As mentioned above, the rigid portion 236 can comprise, in some embodiments, aluminum or a suitable composite material. The string core 232 can be strung on one or both sides of the rigid portion 236. As shown in FIG. 7 , the core material 228 is disposed within the rigid portion 236. In embodiments wherein the string core 232 is strung on both sides of the rigid portion 236, the string core 232 and the rigid portion 236 surround an interior volume that houses the core material 228. The core material 228 can comprise any of polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams, honeycombs, and the like, without limitation. As further shown in FIG. 7 , a rigid layer 220 is disposed outside the core material 228 and the string core 232. The rigid layers 220 can comprise multilayer carbon fiber, fiberglass, or another similar material, without limitation. It is contemplated that, in some embodiments, the paddle 224 can be wrapped within a skin layer 168, as described herein.
As mentioned hereinabove, it is contemplated that any of various structures may be incorporated into the planar portion before being wrapped in the skin layers 168, as described herein. For example, FIG. 8 illustrates an exemplary embodiment of a paddle 240 that includes a structured planar portion 244 and a handle portion 248 in accordance with the present disclosure. The planar portion 244 and the handle portion 248 have rounded edges 252, as described herein. The planar portion 244 comprises a core 256 surrounded by a rigid portion 260. The core 256 and the rigid portion 260 may comprise any of various materials that are found to provide a product that can be more efficiently produced, that is more aesthetically pleasing, that provides greater consistency of function, and is more reliable than products produced using other technologies. In one exemplary embodiment, the rigid portion 260 comprises between 20-lb. and 24-lb. foam, while the core 256 comprises a honeycomb structured material.
It should be understood that the core 256 can be implemented with various different shapes in the planar portion 244 to achieve performance objectives, such as power, touch, control, and the like. For example, FIG. 8A illustrates an exemplary embodiment of a sports paddle 340 that includes a shaped core material and a rigid portion in accordance with the present disclosure. The paddle 340 is substantially similar to the paddle 240, shown in FIG. 8 , with the exception that the paddle 340 comprises a planar portion 344 that includes a core shape 352 that is surrounded by a rigid portion 356. The core shape 352 includes a core material 360 that can be strategically positioned in the planar portion 344 to provide the performance objectives mentioned above. As shown, for instance, the core shape 352 includes a rounded portion 364 that advantageously affects the performance of the paddle 340. In some embodiments, the rigid portion 356 comprises between 20-lb. and 24-lb. foam, while the core material 360 comprises a honeycomb structured material.
FIG. 8B illustrates another exemplary embodiment of a sports paddle 380 that includes a shaped core material and a rigid portion according to the present disclosure. The paddle 380 is substantially similar to the paddle 340, shown in FIG. 8A, with the exception that the paddle 380 comprises a planar portion 384 that includes a core shape 392 that is surrounded by a rigid portion 396. The core shape 392 includes a core material 400 that can be strategically positioned in the planar portion 384 to provide the performance objectives mentioned with respect to FIG. 8A. For example, the core shape 392 comprises a window-like structure that occupies relatively little space on the planar portion 384, thus providing a planar portion 384 that exhibits a greater degree of rigidity than the paddle 340 shown in FIG. 8A. Further, the rigid portion 396 may comprise between 20-lb. and 24-lb. foam, while the core material 400 comprises a honeycomb structured material.
FIG. 9 illustrates an exemplary embodiment of a paddle 264 that includes a structured planar portion 268 and a handle portion 272 in accordance with the present disclosure. The paddle 264 is substantially similar to the paddle 240 shown in FIG. 8 , with the exception that the paddle 264 of FIG. 9 includes a planar portion 268, a handle portion 272, and a padded edge guard 276. The planar portion 268 and the handle portion 272 have rounded edges 252, as described herein. The planar portion 268 comprises a core 256 surrounded by a rigid portion 260, as described with respect to FIG. 8 . The core 256 and the rigid portion 260 may comprise any of various materials that are found to provide a product that can be more efficiently produced, that is more aesthetically pleasing, that provides greater consistency of function, and is more reliable than products produced using other technologies. It is contemplated that the padded edge guard 276 may be bonded to a periphery of the rigid portion 260 before the skin layer 168 is applied to the planar portion 268. As such, the padded edge guard 276 can provide protection to the edge of the paddle 264 without any need for the bulky edge guard 112 discussed in connection with FIG. 1 .
Moreover, it is contemplated that an edge guard may be bonded to the periphery of the rigid portion 260 after the skin layer 168 is applied to the planar portion 268. FIG. 11A illustrates an exemplary embodiment of an edge guard 280 that may be coupled with an exterior of the periphery of the rigid portion 260. The edge guard 280 is configured to provide protection to the portions of the skin layer 168 that are disposed on the rounded edges 252. As shown in FIG. 11A, the edge guard 280 comprises a polymer portion 284 and a mass strip portion 288. The polymer portion 284 may be made of polyurethane or any other material that is suitable for protecting the rounded edges of the paddle 264. In the embodiment of FIG. 11A, the polymer portion 284 includes a rounded surface 292 that may be configured to smoothly join with the rounded edges 252 to produce a low-profile edge rail for the paddle 264. The mass strip 288 preferably comprises a thin strip of metal, such as lead, that may be used to increase the weight of the paddle 264. As shown in FIG. 11A, the mass strip 288 may be coupled with a flat surface 296 of the polymer portion 284. The mass strip 288 may be adhered to the flat surface 296 by way of any of various suitable adhesives. Further, the mass strip 288 and exposed portions of the flat surface 296 may be adhered to the periphery of the paddle 264 by way of any of various suitable adhesives, without limitation.
FIG. 11B illustrates an exemplary embodiment of an edge guard 300 that may be coupled with an exterior of the periphery of the rigid portion 260. The edge guard 300 is substantially similar to the edge guard 280 shown in FIG. 11A, with the exception that the edge guard 300 comprises a polymer portion 304 that includes a recess 308 for receiving the mass strip 288. The mass strip 288 may be adhered within the recess 308 by way of any suitable adhesive. As shown in FIG. 11B, the recess 308 is configured to receive the mass strip 288 such that the flat surface 296 and a back surface 312 of the mass strip 288 form a substantially uniform surface suitable for being adhered to the periphery of the paddle 264. The surfaces 296, 312 may be adhered to the periphery of the paddle 264 by way of any suitable adhesive, without limitation. It is contemplated that disposing the mass strip 288 within the recess 308 will allow the rounded surface 292 of the edge guard 300 to smoothly join with the rounded edges 252 to produce a low-profile edge rail for the paddle 264.
With reference, again, to FIGS. 8-9 , it should be borne in mind that the planar portion 268 is not limited to honeycomb structures. For example, in some embodiments, the planar portion 268 may comprise a solid portion of rigid foam, such as the abovementioned 20-24 lb. foam. Further, in some embodiments, the planar portion 268 may include a core 256 comprising a different type or density of foam than the foam comprising the rigid portion 260. In some embodiments, the core 256 may comprise a number of holes advantageously positioned on the rigid portion 260 to reduce the weight of the paddle 264.
In some embodiments, one or more weights may be incorporated into the planar portion to increase the weight of the paddle. For example, FIG. 10 illustrates an exemplary embodiment of a paddle 316 that includes multiple weights according to the present disclosure. The paddle 316 includes a planar portion 320 that extends to a handle portion 324. Rounded edges 252 are disposed along all exterior edges of the planar portion 320 and the handle portion 324. As shown in FIG. 10 , the planar portion 320 comprises a rigid portion 328 that includes multiple weights 332. Although four weights 332 are shown, it is contemplated that the planar portion 320 may include any number of weights 332. Further, any size and/or mass of the weights 332 may be disposed in any of various locations of the planar portion 320, without limitation.
FIGS. 12 and 12A illustrate an exemplary embodiment of a paddle 420 that includes a structured planar portion 424 and a handle portion 428 in accordance with the present disclosure. The planar portion 424 and the handle portion 428 have rounded edges 252, as described herein. The planar portion 424 comprises multiple stringers 432 that are embedded in a core 436. The core 436 and the stringers 432 may comprise any of various materials that are found to provide a product that can be more efficiently produced, that is more aesthetically pleasing, that provides greater consistency of function, and is more reliable than products produced using other technologies. As shown in FIG. 12A, in some embodiments, the stringers 432 may comprise strips of wood or plastic that are glued into honeycomb or foam comprising the core 436. It is contemplated that the rigidity of the stringers 432 can be used to provide a stronger planar portion 424. More specifically, the stringers 432 may be used to enhance strength and core stability, facilitate customizable weight distributions, depending on stringer placement or material, improve rebound due to higher durometer materials, and boost durability by reinforcing weaker areas of the core 436. In some embodiments, however, the stringers 432 may comprise rubber, a foam, or other suitable material that can provide a flexible planar portion 424.
It should be borne in mind that the paddle 420 is not limited to the number of stringers 432 shown in FIG. 12 . Rather, any number of stringers 432 can be incorporated into the core 436 to provide a paddle 420 that exhibits the desired performance. For example, in some embodiments, the paddle 420 can include a single stringer 432 that extends along the midline of the paddle 420. In some embodiments, the paddle 420 can include the single stringer 432 along the midline of the paddle 420 and two or more shorter stringers 432 that extend across the planar portion 424 parallel to the single stringer 432.
Moreover, it is contemplated that, in some embodiments, the stringers 432 can be embedded into the planar portion 424 in different patterns that are found to provide desired performance results, such as enhanced power and control, improved balance and feel, and extended product life. FIG. 13 , for example, illustrates an exemplary embodiment of a paddle 440 that includes curved stringers 444 embedded into a planar portion 448 according to the present disclosure. Similar to the paddle 420, shown in FIG. 12 , the paddle 440 includes rounded edges 252 disposed around the planar portion 448 and a handle portion 452. The planar portion 448 comprises multiple curved stringers 444 that are embedded in a core 456. As described with respect to FIG. 12A, in some embodiments, the curved stringers 444 may comprise strips of wood or plastic that are glued into honeycomb or foam comprising the core 456.
FIG. 14 illustrates an exemplary embodiment of a paddle 460 that includes curved stringers 464 embedded into a planar portion 468 accordance with the present disclosure. Similar to the paddle 440, shown in FIG. 13 , the paddle 460 includes rounded edges 252 disposed around the planar portion 468 and a handle portion 472. The planar portion 468 comprises multiple curved stringers 464 that are embedded in a core 476. It is contemplated that the curved stringers 464 may comprise strips of wood or plastic that are glued into honeycomb or foam comprising the core 476. As will be appreciated, the curved stringers 464 comprise a different orientation than the curved stringers 444 shown in FIG. 13 . It is contemplated that the curved stringers 464, 444 can be arranged in any of various orientations and curvatures that are found to provide desired performance characteristics, without limitation.
In some embodiments, curved stringers and linear stringers can be combined to form paddles exhibiting desired performance characteristics, such as enhanced power and control, improved balance and feel, and extended product life, as mentioned above. For example, FIG. 14A illustrates an exemplary embodiment of a paddle 560 that includes a combination of curved stringers 564 and linear stringers 568 that are embedded into a planar portion 448 according to the present disclosure. Similar to the paddle 440, shown in FIG. 13 , the paddle 560 includes rounded edges 252 disposed around the planar portion 448 and a handle portion 452. The planar portion 448, shown in FIG. 14A, comprises multiple curved stringers 564 and linear stringers 568 arranged to resemble a reticle that is embedded in a core 456. The curved and linear stringers 564, 568 may comprise strips of wood or plastic that are glued into honeycomb or foam comprising the core 456.
FIG. 14B illustrates an exemplary embodiment of a paddle 580 that includes a combination of circular stringers 584 and elliptical stringers 588 that are embedded into a planar portion 468 accordance with the present disclosure. Similar to the paddle 460, shown in FIG. 14 , the paddle 580 includes rounded edges 252 disposed around the planar portion 468 and a handle portion 472. In the embodiment of FIG. 14B, the planar portion 468 comprises multiple circular stringers 584 that are concentric with multiple elliptical stringers 588 that are all embedded in a core 476. As stated hereinabove, the circular and elliptical stringers 584, 588 may comprise strips of wood or plastic that are glued into honeycomb or foam comprising the core 476. In general, it should be appreciated that the stringers can be implemented in a wide variety of shapes and can be arranged in the core 476 with any of various orientations and curvatures that are found to provide desired performance characteristics, without limitation.
FIG. 15 illustrates an exemplary embodiment of a paddle 480 that includes multiple stabilizer slugs or balance slugs according to the present disclosure. The paddle 480 includes a planar portion 484 that extends to a handle portion 488. Rounded edges 252 are disposed along all exterior edges of the planar portion 484 and the handle portion 488. The planar portion 484 comprises a rigid portion 492 that includes multiple weights 496 and multiple stabilizers 498. As will be appreciated, in some embodiments, the stabilizers 498 can comprise differently sized and/or shaped weights than the weights 496. In some embodiments, one or more of the weights 496 and the stabilizers 498 may comprise different materials. In some embodiments, the weights 496 and the stabilizers 498 comprise slugs of gel rubber or a heavier material to weigh the paddle 480 or create dampening of vibration or both. Although two weights 496 and two stabilizers 498 are shown, it is contemplated that the planar portion 484 can include any number or combination of weights 496 and stabilizers 498. Further, any size and/or mass of the weights 496 and the stabilizers 498 can be disposed in any of various locations of the planar portion 484, without limitation.
It is contemplated that, in some embodiments, the weights 496 and/or the stabilizers 498 can extend partially or completely through the thickness of the planar portion 484. For example, in an embodiment shown in FIG. 15A, the weights 496 extend through a core 500 comprising the planar portion 484 and have a thickness 504 that is equal to the thickness of the planar portion 484. Thus, once the paddle 480 is wrapped in skin layers 168, as described herein, the weights 496 and the planar portion 484 provide a flat paddle surface, as shown in FIG. 3 . Similarly, it is contemplated that any one or more of the stabilizers 498 can be configured to extend through the core 500 as shown and discussed with respect to the weights 496.
Moreover, the weights 496 and/or the stabilizers 498 need not extend all the way through the core 500. For example, in an embodiment of the planar portion 508, shown FIG. 15B, a first weight 512 and a second weight 516 can be embedded on opposite sides of the core 500, such that the weights 512, 516 and the planar portion 508 provide a flat paddle surface once the paddle 480 is wrapped in skin layers 168. Further, although the first and second weights 512, 516 are shown in FIG. 15B as having the same size, in some embodiments, the first and second weights 512, 516 can have different shapes and sizes, as desired, without limitation.
FIG. 16 illustrates an exemplary embodiment of a paddle 520 that includes channels or holes according to the present disclosure. The paddle 520 includes a planar portion 524 that extends to a handle portion 528. Rounded edges 252 are disposed along all exterior edges of the planar portion 524 and the handle portion 528. The planar portion 524 includes a rigid portion that comprises a core 532 that includes multiple channels 536. The channels 536 can be arranged in any of various patterns, without limitation, that are found to desirably enhance the performance of the paddle 520.
Moreover, any one or more of the channels 536 can extend partially or all the way through the core 532. In an embodiment, shown in FIG. 16A, for example, a channel 536 extends all the way through the core 532. In an embodiment, shown in FIG. 16B, however, a first channel 540 and a second channel 544 are disposed on opposite sides of the planar portion 524, leaving a relatively thin portion of the core 532 to separate the first and second channels 540, 544. In some embodiments, a rigid layer, such as the rigid layers 220 of FIG. 7 , can be disposed outside the core 532 to cover the channels 536. The rigid layers 220 can comprise multilayer carbon fiber, fiberglass, or another similar material, without limitation. Thus, once the paddle 520 is wrapped in skin layers 168, as described herein, the rigid layers will provide a flat paddle surface.
While the paddle and methods have been described in terms of particular variations and illustrative figures, those of ordinary skill in the art will recognize that the paddle is not limited to the variations or figures described. In addition, where methods and steps described above indicate certain events occurring in certain order, those of ordinary skill in the art will recognize that the ordering of certain steps may be modified and that such modifications are in accordance with the variations of the paddle. Additionally, certain of the steps may be performed concurrently in a parallel process, when possible, as well as performed sequentially as described above. To the extent there are variations of the paddle, which are within the spirit of the disclosure or equivalent to the paddle found in the claims, it is the intent that this patent will cover those variations as well. Therefore, the present disclosure is to be understood as not limited by the specific embodiments described herein, but only by scope of the appended claims.

Claims

What is claimed is:

1. A sports paddle, comprising:

a planar portion having opposing flat surfaces for striking a ball;

a core material having rounded edges;

a handle portion for grasping in a hand; and

a skin layer surrounding at least a majority of the planar portion.

2. The sports paddle of claim 1, wherein the planar portion includes a shaped core material and a rigid portion.

3. The sports paddle of claim 2, wherein the shaped core material comprises a window-like structure that provides a planar portion that exhibits a relatively greater degree of rigidity.

4. The sports paddle of claim 1, wherein one or more weights are incorporated into the planar portion to increase the weight of the paddle.

5. The sports paddle of claim 4, wherein any one or more of the one or more weights comprises a stabilizer that provides desired performance results.

6. The sports paddle of claim 5, wherein any one or more of the multiple weights and the stabilizers comprise slugs of gel rubber for weighing the paddle and/or creating a dampening of vibration.

7. The sports paddle of claim 5, wherein any one or more of the multiple weights and the stabilizers comprises a first weight and a second weight that are embedded on opposite sides of the core.

8. The sports paddle of claim 1, wherein the planar portion comprises multiple stringers that are embedded in the core material.

9. The sports paddle of claim 8, wherein the multiple stringers comprise strips of wood or plastic that are glued into the core material.

10. The sports paddle of claim 8, wherein the multiple stringers comprise rubber, a foam, or another suitable material that provides a flexible planar portion.

11. The sports paddle of claim 8, wherein one or more of the multiple stringers comprises a curved stringer that is embedded into the planar portion.

12. The sports paddle of claim 1, wherein the planar portion comprises a rigid portion that includes a core material having one or more channels that are arranged in a pattern that desirably enhances the performance of the paddle.

13. The sports paddle of claim 12, wherein any one or more of the one or more channels extends all the way through the core material.

14. The sports paddle of claim 12, wherein any one or more of the one or more channels comprises a first channel and a second channel that are disposed on opposite sides of the planar portion, leaving a relatively thin portion of the core material disposed between the first channel and the second channel.

15. The sports paddle of claim 1, wherein the planar portion includes an internal string core surrounded by structured foam layers.

16. The sports paddle of claim 15, wherein the string core is strung on a rigid portion comprising carbon fiber, aluminum, or another similar material capable of supporting the string core.

17. The sports paddle of claim 15, wherein a rigid layer is disposed outside each structured foam layer.

18. The sports paddle of claim 1, wherein the planar portion includes a core material surrounded by an external string core that is strung around the exterior of a rigid portion.

19. The sports paddle of claim 18, wherein the rigid portion comprises carbon fiber, aluminum, or another similar material.

20. The sports paddle of claim 18, wherein the external string core and the rigid portion surround an interior volume that houses the core material.